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Lexmark and Lexmark with diamond

design are trademarks of Lexmark

International, Inc., registered in the

United States and/or other countries.

Table of Contents

Index

Safety and Notices

Trademarks

Start Diagnostics

Lexmark X125All-In-One

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Edition: March 24, 2006

The following paragraph does not apply to any country where such provisions are

inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THISPUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR

IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF

MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do

not allow disclaimer of express or implied warranties in certain transactions; therefore, this

statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes are

periodically made to the information herein; these changes will be incorporated in later

editions. Improvements or changes in the products or the programs described may be

made at any time.

Comments may be addressed to Lexmark International, Inc., Department D22A/032-2,

740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at

[email protected]. Lexmark may use or distribute any of the

information you supply in any way it believes appropriate without incurring any obligation

to you.

Lexmark and Lexmark with diamond design are trademarks of Lexmark International,

Inc., registered in the United States and/or other countries.

Other trademarks are the property of their respective owners.

Copyright Lexmark International, Inc. 2002.All rights reserved.

UNITED STATES GOVERNMENT RESTRICTED RIGHTS

This software and documentation are provided with RESTRICTED RIGHTS. Use,

duplication or disclosure by the Government is subject to restrictions as set forth in

subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at

DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc.,

Lexington, KY 40550.

4412-00X

P/N 12G9185

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iii

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Table of Contents

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Printer Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Facsimile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Scanner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Power and Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Power-On Self Test (POST) Sequence . . . . . . . . . . . . . . . . . 2-1POST Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Symptom Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Carrier Transport Service Check. . . . . . . . . . . . . . . . . . . . . . . 2-7CIS Assembly Service Check . . . . . . . . . . . . . . . . . . . . . . . . . 2-9Scanner Motor with Gear Assembly Service Check . . . . . . . 2-10Maintenance Station Service Check . . . . . . . . . . . . . . . . . . . 2-11Paper Feed Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12Paper Path Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14Power Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15Print Quality Service Check . . . . . . . . . . . . . . . . . . . . . . . . . 2-16Scan/Copy Quality Service Check . . . . . . . . . . . . . . . . . . . . 2-18Fax/Telephone Communication Service Check . . . . . . . . . . 2-19

Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Theory of Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Scanner Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Drive Feed Roller Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Contact Image Sensor (CIS) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Document Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Removal Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
http://-/?-http://-/?-http://-/?-http://-/?-

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Releasing Plastic Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

General Precautions on Removals. . . . . . . . . . . . . . . . . . . . . .4-3CIS White Roller Assembly Removal . . . . . . . . . . . . . . . . . . . .4-4Top Cover Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . .4-5Rollers (Drive Feed Roller Assembly, Exit Shaft) Removal. . .4-6CIS (Contact Image Sensor) Removal . . . . . . . . . . . . . . . . . . .4-7Scanner Motor with Gear Assembly Removal. . . . . . . . . . . . .4-9Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11Line Interface Board Removal. . . . . . . . . . . . . . . . . . . . . . . .4-12Operator Panel Assembly Removal . . . . . . . . . . . . . . . . . . . .4-13Printer Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

ASF Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15Maintenance Station Removal . . . . . . . . . . . . . . . . . . . . . . . .4-17Carrier Assembly with Belt Removal . . . . . . . . . . . . . . . . . . .4-18System Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19Mid Frame Assembly with Exit Rollers Removal . . . . . . . . . .4-20Large Feed Roller Assembly with Gear Removal . . . . . . . . .4-21Paper Feed Motor Assembly with Gears Removal . . . . . . . .4-22Carrier Transport Motor Removal. . . . . . . . . . . . . . . . . . . . . .4-23

Connector Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

System Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1Line Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

How to Use This Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

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Safety Information

The safety of this product is based on testing and approvals ofthe original design and specific components. The manufactureris not responsible for safety in the event of use of unauthorized

replacement parts.

The maintenance information for this product has beenprepared for use by a professional service person and is not

intended to be used by others.

There may be an increased risk of electric shock and personal

injury during disassembly and servicing of this product.Professional service personnel should understand this and take

necessary precautions.

Consignes de Scurit

La scuritde ce produit repose sur des tests et desagrations portant sur sa conception d'origine et sur des

composants particuliers. Le fabricant n'assume aucune

responsabilitconcernant la scuriten cas d'utilisation de

pices de rechange non agres.

Les consignes d'entretien et de rparation de ce produits'adressent uniquement un personnel de maintenance

qualifi.

Le dmontage et l'entretien de ce produit pouvant prsenter

certains risques lectriques, le personnel d'entretien qualifidevra prendre toutes les prcautions ncessaires.

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Norme di sicurezza

La sicurezza del prodotto si basa sui test e sull'approvazione

del progetto originale e dei componenti specifici. Il produttorenon responsabile per la sicurezza in caso di sostituzione non

autorizzata delle parti.

Le informazioni riguardanti la manutenzione di questo prodottosono indirizzate soltanto al personale di assistenza autorizzato.

Durante lo smontaggio e la manutenzione di questo prodotto,il rischio di subire scosse elettriche e danni alla persona pi

elevato. Il personale di assistenza autorizzato, deve, quindi,

adottare le precauzioni necessarie.

Sicherheitshinweise

Die Sicherheit dieses Produkts basiert auf Tests undZulassungen des ursprnglichen Modells und bestimmter

Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird

vom Hersteller keine Verantwortung oder Haftung fr dieSicherheit bernommen.

Die Wartungsinformationen fr dieses Produkt sindausschlielich fr die Verwendung durch einen

Wartungsfachmann bestimmt.

Whrend des Auseinandernehmens und der Wartung desGerts besteht ein zustzliches Risiko eines elektrischen

Schlags und krperlicher Verletzung. Das zustndige

Fachpersonal sollte entsprechende Vorsichtsmanahmentreffen.

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Pautas de Seguridad

La seguridad de este producto se basa en pruebas y

aprobaciones del diseo original y componentes especficos.El fabricante no es responsable de la seguridad en caso de uso

de piezas de repuesto no autorizadas.

La informacin sobre el mantenimiento de este producto estdirigida exclusivamente al personal cualificado de

mantenimiento.

Existe mayor riesgo de descarga elctrica y de daospersonales durante el desmontaje y la reparacin de la

mquina. El personal cualificado debe ser consciente de estepeligro y tomar las precauciones necesarias.

Informaes de Segurana

A segurana deste produto baseia-se em testes e aprovaesdo modelo original e de componentes especficos. O fabricante

no responsvel pela segunrana, no caso de uso de peasde substituio no autorizadas.

As informaes de segurana relativas a este produtodestinam-se a profissionais destes servios e no devem ser

utilizadas por outras pessoas.

Risco de choques elctricos e ferimentos graves durante adesmontagem e manuteno deste produto. Os profissionais

destes servios devem estar avisados deste facto e tomar os

cuidados necessrios.

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Informacide Seguretat

La seguretat d'aquest producte es basa en l'avaluacii

aprovacidel disseny original i els components especfics.El fabricant no es fa responsable de les qestions de

seguretat si s'utilitzen peces de recanvi no autoritzades.

La informacipel manteniment daquest producte estorientada exclusivament a professionals i no estdestinada

a ningque no ho sigui.

El risc de xoc elctric i de danys personals pot augmentardurant el procs de desmuntatge i de servei daquest producte.

El personal professional ha destar-ne assabentat i prendreles mesures convenients.

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Preface

This manual and contains maintenance procedures for servicepersonnel. It is divided into the following chapters:

1. General Informationcontains a general description of the

printer and the maintenance approach used to repair it. Special

tools and test equipment are listed in this chapter, as well as

general environmental and safety instructions.

2. Diagnostic Informationcontains an error indicator table,

symptom tables, and service checks used to isolate failing field

replaceable units (FRUs).

3. Diagnostic Aidscontains tests and checks used to locate or

repeat symptoms of printer problems.

4. Repair Informationprovides instructions for making printer

adjustments and removing and installing FRUs.

5. Connector Locationsuses illustrations to identify the

connector locations and test points on the printer.

6. Preventive Maintenancecontains the lubrication specificationsand recommendations to prevent problems.

7. Parts Catalogcontains illustrations and part numbers for

individual FRUs.

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General Information 1-1

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1. General Information

The LexmarkX125 All-In-One (4412-00X) is a letter quality print,fax, copy, and scan machine. The printhead uses small heater plates

and nozzles to control ink flow and the formation of characters on

the print media. The printhead assembly and ink supply are

combined into a single unit. Print cartridges are available as a

customer replaceable supply item. Dual printheads provide color

and true black printing without changing printheads. The number

and size of inkjets or nozzles, in the printhead, determines the

overall quality and capability of the printer. The black cartridge has a

total of 208 nozzles and installs on the right. The color cartridge has

a total of 192 nozzles and installs on the left. The printer is capable

of printing in both directions from either cartridge.

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1-2 Service Manual

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Specifications

Printer Engine

Printhead

Technology Thermal Inkjet

2-pin and printhead swappingtype

Speed Color 8 ppm at Draft Mode

Mono 16 ppm at Draft Mode

Resolution Color 600 X 600 dpi (1200 X 2400dpi addressable)

Mono 600 X 600 dpi (1200 X 2400dpi addressable)

Printing Width 203 mm

Feeding Method Automatic 100 sheets of 20 lb cut sheets(Max 10 mm)

Manual Tray No

Emulation Host Based Printing (GDI)

Printer Driver Windows 98/ME, Windows2000/Windows XP

Interface USB Interface

Babbage Mono Standard Birch Color

Printhead 208 nozzles 192 nozzles

Ink Type Pigment Dye

Ink Color Black Color

Ink Yield About 600 sheets About 200 sheets

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Facsimile

General Compatibility ITU-G3

Scan Method CIS

Scan Width Maximum 216 mm, Effective 210 mm

Scan Resolution 600 X 1200 dpi

Scan Speed 6 seconds

Feeding Method Sheet Feed

ADF 30 sheets of 20 lb

Guide Document Input Guide

Stacker Document Output Stacker/PaperStacker

Paper Tray Bin Type (without Manual Tray)

Modem Speed 33.6 Kbps

Coding Method MH, MR, MMR, Error Correction Mode

LCD 2 lines of 16 characters each

Scanning Resolution andType

Standard: 200 X 100 dpiFine: 200 X 200 dpi (default)Super Fine: 300 X 300 dpiColor: 200 X 200 dpi

(Standard: Low quality, Fine: Highquality compression)

Contrast Darkest/Darken/NormalLighten/Lightest

Memory Capacity 1 Mbyte

Back-up Time 15 sec (Continuous power failure,typically 1-2 minutes)

Confidential No

Forced Memory TX Yes

Memory RX Automatic reception when paper empty.

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1-4 Service Manual

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Telephone Speed Dial 70 locations

Chain Dial No

On-Hook Dial Yes, 1-Key

Last Number Redial Yes, 1-Key

Auto Redial Yes

Hold and Mute No

Pause Yes, use Redial Key

Ringer Volume S/W Option Setting (4 steps)

Tone/Pulse Select S/W Option Setting

DRPD USA: Yes, Other Countries: Yes

Report andList

TX/RX Journal Yes

Image TCR Yes, reduction of first page sent byMemory TX

System Data Yes

Telephone NumberList

Yes

Self Test Yes

Copy Multipage Copy Up to 99 pages

Grayscale 256 levels

Reduction andEnlargement

25% - 200%(Reference is the top center ofdocument.)

TelephoneI/F

Answering I/F Yes

Extension Phone 1-jack, extension phone transfer

Others Sensors Paper Jam

Real-Time Clock No

RTI Yes

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Scanner

Power and Size

Abbreviations

Compatibility TWAIN

Technology Platen CIS

Light Source for Color CIS RGB LEDs (Line Order Control)

Power Source 110V-240V / 50Hz-60Hz

Dimensions 440.6 X 319.6 X 205.4 mm

Weight (Packed) 15.3 lbs (Packed Weight)

ASF Auto Sheet Feed

B/M Bill of Material

CIS Contact Image Sensor

EOF End of Form

ESD Electrostatic Discharge

FPC Flat Printhead Cable

FRU Field Replaceable Unit

HVPS High Voltage Power Supply

LCD Liquid Crystal Display

LVPS Low Voltage Power SupplyOEM Original Equipment Manufacturer

V ac Volts alternating current

V dc Volts direct current

ZIF Zero Insertion Force

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1-6 Service Manual

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Diagnostic Information 2-1

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2. Diagnostic Information

Start

Power-On Self Test (POST) Sequence

1. Power Up Please Wait is displayed on the LCD.

2. Carrier moves to the left and the paper feed motor runs then

stops.

3. Carrier returns to the right.4. Ready, ANS/FAX, and the Date and Time display when POST is

complete.

If your printer completes POST with no errors, go to the SymptomTableson page 2-3. Locate the symptom and take the indicatedaction.

If your printer does not complete POST, locate the symptom in the

following table and take the indicated action.

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POST Symptom Table

Symptom Action

LCD or operatorpanel buttons donot work and nomotors run

Go to the Power Service Checkon page 2-15. If okay,go to the Operator Panel Problemson page 2-3.

Paper feedgears do notturn

Go to the Paper Feed Service Checkon page 2-12.

Carrier does notmove

Go to the Carrier Transport Service Checkonpage 2-7.

Carrier slamsside frame

Go to the Carrier Transport Service Checkonpage 2-7.

CIS light doesnot turn on

Go to the CIS Assembly Service Checkon page 2-9.

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Symptom Tables

Locate the symptom in the following tables and take the appropriate

action.

Carrier Transport Problems

Maintenance Station Problems

Operator Panel Problems

Symptom Action

No carrier movement Slow carrier movement Carrier stops

Carrier slams side frame

Go to the Carrier TransportService Checkon page 2-7.

Symptom Action

Maintenance station:

Fails to cap the printheads Fails to clean the printheads

Go to the Maintenance StationService Checkon page 2-11.

Symptom Action

Buttons do not work

LCD does not display

Check operator panel cable

connection at P9 on the systemboard. Run the Power-On SelfTest (POST) Sequenceonpage 2-1. If the LCD or buttons fail,check connection P9. If the problemremains, replace the operator panelassembly. Go to the OperatorPanel Assembly Removalonpage 4-13.

If the problem still exists, replace thesystem board. Go to the SystemBoard Removalon page 4-19.

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Document scan sensor does not

detect document

Check operator panel cable

connector P9 on the system board. Ifokay, go to the Scanner Motorwith Gear Assembly ServiceCheckon page 2-10. If thescanner motor is working correctly,replace the operator panel assembly.Go to the Operator PanelAssembly Removalon page 4-13.

Symptom Action

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Printer Communication Problem

Scanner Problems

Symptom Action

Not able to print Self Test Page Check the USB cable and systemboard cable connections. If okay,replace system board. Go to theSystem Board Removalonpage 4-19.

Symptom Action

Light does not turn on Go to the CIS Assembly ServiceCheckon page 2-9.

Scanned images are faded, orcolors are dull, blurry or fuzzy.Images are slanted or crookedand the straight lines in the

image appear to be jagged oruneven.

Blank copies

Go to the Scan/Copy QualityService Checkon page 2-18.

Scanner motor does not run Document sensor does not

work

Go to the Scanner Motor withGear Assembly Service Checkon page 2-10.

Go to the Operator PanelProblemson page 2-3.

CIS white roller assembly slips Paper does not feed correctly

Go to the Paper Path ServiceCheckon page 2-14.

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Paper Feed Problems

Power Problems

Print Quality Problems

Symptom Action

Fails to pick paper Picks more than one sheet of

paper Picks paper but fails to feed Paper jams Paper fails to exit Noisy paper feed

Go to the Paper Feed ServiceCheckon page 2-12.

Envelopes fail to feed Go to the Paper Feed Service

Checkon page 2-12.

Paper skews Go to the Paper Path ServiceCheckon page 2-14.

Symptom Action

No power in machine, motors donot operate

Go to the Power Service Checkon page 2-15.

Symptom Action

Voids in characters Light print Prints off the page Fuzzy print Carrier moves but no print Printhead dries prematurely Colors print incorrectly Vertical alignment off

Go to the Print Quality ServiceCheckon page 2-16.

Ink smearing

Vertical streaks on paper Print lines crowded

Go to the Paper Feed Service

Checkon page 2-12.

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Service Checks

Carrier Transport Service Check

FRU Action

1 System Board

Carrier TransportMotor

Check the carrier transport motor connector P4. Ifconnected, check for approximately 29 volts onpins 1 and 2 or at the wire connections located onthe rear of the carrier transport motor. If voltage isincorrect, replace the system board. If voltage iscorrect, check the motor for shorts.

2 Carrier TransportMotor

Check the motor for binds, or loose motor pulley.

A noisy or chattering motor, or a motor that fails toturn, can be caused by:

An open or short in the motor An open or short in the motor driver

on the system board

A bind in the carrier transportmechanism

With the carrier transport motor cable (P4)disconnected from the system board, check for 0to 16 ohms between the following pins on themotor:

P4-1 and P4-2

If the readings are incorrect, replace the printengine. Go to the Carrier Transport MotorRemovalon page 4-23.

3 Carrier Guide Rod Clean the carrier rod.

Note: Lubricate the rod and the carrier rod bearingsurfaces with grease P/N 99A0394.

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4 Encoder Strip

Carrier Assemblywith Belt

Check the encoder strip for proper installation.

Also, check it for wear, dirt, and grease. Replace ifneeded.

Be sure all printhead connectors are fully seated.Check the cables for damage.

If the encoder strip and all connections are okay,but the carrier still slams the side frame, replacethe carrier assembly with belt. Go to the CarrierAssembly with Belt Removalon page 4-18. If

problem remains, replace the system board. Go tothe System Board Removalon page 4-19.

5 Carrier TransportBeltIdler PulleyAssembly

Check for worn, loose or broken parts. Check forobstructions blocking carrier movement. If pulleyassembly is damaged, replace.

Lubricate carrier to carrier frame engagement withgrease P/N 99A0394.

6 MaintenanceStation A problem with the maintenance station can causecarrier movement problems at the right margin. Goto the Maintenance Station Removalonpage 4-17.

7 Access DoorSensor

If the carrier does not move toward the cartridgeload position when the access door is opened,verify that power is on. If the carrier still does notmove, check connector P11 pin 1 forapproximately 3 volts, with the door open. If the

voltage is correct, replace the sensor. DisconnectP11 from the system board before removingsensor. If the voltage is incorrect, replace thesystem board. Go to the System BoardRemovalon page 4-19.

FRU Action

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CIS Assembly Service Check

The CIS lamp does not light when scanning is in process.

FRU Action

1 CIS Assembly If light does not come on during thescanning process, check connectorP2 on the system board. If theconnection is okay, check for a

voltage reading of approximately 4volts from ground to P2-2 pin. Ifvoltage is correct, replace the CISassembly. Go to the CIS (ContactImage Sensor) Removalonpage 4-7.If voltage is incorrect,replace the system board. Go to theSystem Board Removalonpage 4-19.

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2-10 Service Manual

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Scanner Motor with Gear Assembly Service Check

Motor will not run.

FRU Action

1 Scanner Motor with GearAssembly

Check scanner motor for shorts.Disconnect connector P6 from thesystem board and check forapproximately 6 ohms between thefollowing pins on the motorconnector.

P6-1 and P6-2

If the ohms reading is incorrect,replace the scanner motor assembly.If the motor does not come on duringthe scanning process, checkconnector P6 on the system board. Ifthe connection is okay, check forvoltage reading of approximately 29volts at pins

P6-1P6-2P6-3P6-4

If voltage is correct, replace thescanner motor with gear assembly.Go to the Scanner Motor withGear Assembly Removalonpage 4-9. If voltage is incorrect,

replace the system board. Go to theSystem Board Removalonpage 4-19.

2 Document Scanner Sensor To check the document scannersensor, insert a sheet of paper orpress the sensor to see if thescanner motor is working. Go toOperator Panel Problemsonpage 2-3.

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Maintenance Station Service Check

The maintenance station has three functions:

1. Wipes the printhead nozzles to clean them of dirt.

2. Provides a place for printheads to fire all nozzles, keeping them

clear prior to printing.

3. Seals the printhead when it is not being used to prevent the

nozzles from drying.

FRU Action

1 MaintenanceStation Assembly

As the carrier moves to the right over themaintenance station, a slot on the bottom of thecarrier engages a tab on the sled of themaintenance station causing the cap to rise andseal the printhead. Carrier movement to the leftuncaps the printhead. The wiper cleans theprinthead nozzles as the carrier leaves the

maintenance station. The wiper cleans theprinthead only when the carrier is moving to theleft. Do not wipe the printhead nozzles when thecarrier is moving to the right. After the cleaningoperation is complete, a tab on the maintenancestation engages a tab on the carrier, causing thewiper to lower.

Check the maintenance station for worn or brokenparts. Replace if needed. Go to the MaintenanceStation Removalon page 4-17.

Worn wipers cause degraded print quality just aftera maintenance cleaning. Check for loose or wornwipers.

Worn caps cause the printhead nozzles to dry andclog. Check for loose or worn caps.

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Paper Feed Service Check

If your machine does not have paper jam problems, continue with

the service check. If your machine does have a paper jam, examine

it for the following before you begin the service check:

Check the entire paper path for obstructions. Be sure there is not too much paper in the sheet feeder. Be sure the correct type of paper is being used. Check for static in the paper.

FRU Action

1 System Board Run the Power-On Self Test (POST) Sequenceon page 2-1. Replace parts as needed. To checkthe paper feed motor, disconnect the paper feedconnector P5 and check for approximately 4 ohmsbetween pins 1 and 4. If the reading is incorrect,replace the paper feed motor assembly with gears.Go to the Paper Feed Motor Assembly withGears Removalon page 4-22. If the reading iscorrect, replace the system board. Go to theSystem Board Removalon page 4-19.

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2 Paper Feed Motor A noisy or chattering motor or a motor that fails to

turn, can be caused by:

An open or short in the motor An open or short in the motor driver on the

system board A bind in the paper feed mechanism

With the paper feed motor cable P5 disconnectedfrom the system board, check for approximately 4ohms between the following pins on the motor:

Pin 1 to Pin 4

If the readings are incorrect, replace the paperfeed motor assembly with gears. Go to the PaperFeed Motor Assembly with Gears Removalonpage 4-22.

Although the paper feeds in a forward directiononly, the paper feed motor turns in two directions.If the paper feed motor turns in one direction only,

replace the system board. Go to the SystemBoard Removalon page 4-19.

Binds in the paper feed motor or gear train cancause intermittent false paper jam errors. Removethe paper feed motor and check the shaft for binds.Also check for a loose or worn motor gear.

3 Auto SheetFeeder Assembly

Check the pick roller for wear.

4 Mid FrameAssembly

Check the following for wear:

Small Feed rollers Large Feed roller Exit roller Star rollers

If the mid frame assembly needs to be replaced,go to the Mid Frame Assembly with ExitRollers Removalon page 4-20.

5 End-of-FormsFlag and Spring

Check for binds or damage.

FRU Action

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Paper Path Service Check

Examine the machine for the following before you begin this service

check:

Check the entire paper path for obstructions. Be sure the correct type of paper is being used. Be sure the printer is installed on a flat surface.

FRU Action

1 Large and SmallFeed Rollers Check for wear and binds.

2 Small Feed RollerSprings

Check for damage or disconnected springs.

3 Auto SheetFeeder Assembly

Check the pick roller for wear.

4 Mid Frame Asm Check the following for wear:

Exit roller Star rollers

5 End-of-FormsFlag

Check for binds or damage.

6 White RollerAssembly

Check for correct installation. Check gear andbushings for damage. If damaged, replace. Go tothe CIS White Roller Assembly Removalonpage 4-4.

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Power Service Check

FRU Action

1 Power Supply Plug the machine into an outlet. Check forapproximately 30 V dc at P1 pin 3. Checkconnector (CON1) at the power supply. If voltage isincorrect, replace the power supply.

2 Printhead CablesPaper Feed MotorCarrier TransportMotor

Operator Panel

Unplug the printer. Disconnect the printheadcables and plug in the printer. Look for a symptomchange. Check the failing part for shorts andreplace as necessary.

Repeat this procedure for the carrier transportmotor, paper feed motor, and operator panel.

3 System Board If the symptom has not changed, replace thesystem board. Go to the System BoardRemovalon page 4-19.

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Print Quality Service Check

FRU / Function Action

1 PrintheadCartridge

Be sure the machine contains good printcartridges.

2 Color PrintheadCartridge CrossContamination

Cross contamination of color inks results inincorrect colors printed, as when green prints foryellow, (when yellow and blue are mixed in theprinthead cartridge). This problem resolves quicklyas the printhead cartridge is used.

If cross contamination occurs, check the following:

The maintenance station wiper for damage. The printhead nozzle plate was resealed with

tape.

3 Carrier Assembly Reseat the printhead cables in the system boardand check the following parts for wear or damage:

Printhead Cartridge Latch

Latch Spring Carrier

4 System BoardCarrierAssembly

Print the self test page. To enter the self test page,press Setupand then Menubutton until PrintReportis displayed. Press Optionsbutton untilSelf Testis displayed. Then press the to print theself test page. Look for a break in the diagonal lineof the nozzle test pattern. A broken line indicatesone or more print nozzles are not working. Run the

test again to verify the failure.

Check the gold-plated contacts on the end of theprinthead carrier cable for dirt, wear, and damage.Use only a clean dry cloth to clean the contacts. Ifa problem is found with contacts on the carrier,replace the carrier. Go to the Carrier Assemblywith Belt Removalon page 4-18.

If the symptom remains, replace the system board.

Go to the System Board Removalonpage 4-19.

5 MaintenanceStation

Intermittent nozzle failures can be caused by wornparts in the maintenance station. Go to theMaintenance Station Removalon page 4-17,and then return to this check.

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6 Paper Feed Ink smudging and smearing can be caused by

paper problems or problems in the paper feedarea.

Check the following:

Correct type of paper is being used. Also checkthe paper for curl or wrinkles.

Feed rollers for wear, dirt, or looseness. Gears for wear or binds. Paper path for obstructions.

7 Carrier Transport Blurred print and voids can be caused by problemsin the carrier transport area. Check the following:

Carrier transport belt for wear. Carrier guide rod for wear or dirt. If dirty, clean

and lubricate. Carrier to carrier frame engagement should be

lubricated with grease P/N 99A0394. Idler pulley parts for wear, damage, or

looseness.

8 Alignment Uneven vertical lines can be adjusted byperforming the printhead alignment adjustments inthe maintenance mode. The user is directed,through the Setting up System in User Modeon page 3-3, to perform the printhead alignmentadjustments, when replacing a printhead cartridge.


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Scan/Copy Quality Service Check


1 Scanned imagesare faded, orcolors are dull,blurry, or fuzzy.Images areslanted orcrooked and thestraight lines inthe image appear

to be jagged oruneven.

Check the lighter/darker settings to see if it iscorrect.

From the operator panel From the Scan & Copy Control Program

Check to see if there is any dust or debris on theglass lens of the CIS. This may cause a poor

image.

2 Blank copies If there are blank copies found, make sure that theoriginal document is facing down.

Check the print cartridges to see if they need to becleaned or replaced.

3 Scanning error Ensure the USB cable is correctly installed.

Ensure the USB cable is proper for USBspecification, version 1.1.

Start the system after twain driver is reinstalled.

If error still occurs, replace the system board. Goto the System Board Removalon page 4-19.

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Fax/Telephone Communication Service Check


1 Line InterfaceBoard or SystemBoard

Cannot maketelephoneconnection toother fax.

No dial tone

Verify correct dialing method (tone or pulse). AreTEL and LINE connections reversed? Verify phonenumber and availability of other fax machine.

Before dialing, press Speakerso you can hear thedialing process. You should hear the ring and a 0.5second 1000 Hz calling tone from your machine, a

1 second pause, then the 3 second 2100 Hz faxresponse tone and a 1650 Hz - 1850 Hz warblinghandshaking tone from the called machine.

Check the connectors on the line interface boardP1 and P2. If okay, check connector CN15 locatedon the system board. If problem still exists, replacethe line interface board. Go to the Line InterfaceBoard Removalon page 4-12. If this does notcorrect the problem, replace the system board. Go

to the System Board Removalon page 4-19.

2 Cannot receivefaxes

Are TEL and LINE connections reversed? Is atelephone on the same line off the hook? Is themachine connected to the wrong telephone line?

Check for a damaged line cord to the machine.Check telephone and line cord connections.

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Diagnostic Aids 3-1

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3. Diagnostic Aids

Theory of Mechanism

Scanner Mechanism

The scanner mechanism consists of components which feed, scan,

and eject the documents that are to be copied or transmitted to a

remote facsimile unit. These components and their functions are

explained below.

Drive Feed Roller Assembly

The drive feed roller assembly, consisting of various rollers, rubber

pad, and springs, automatically separates and feeds the pages of a

document over the scanning area and stacks them on the document

exit tray.

Documents up to 15 pages can be placed in the drive feed roller

assembly for scanning. The leading edge of the document moves

the document detect sensor lever when the operator slides the stack

into the drive feed roller assembly. The scan motor starts to rotate

when the document detect sensor detects the leading edge of the

document. The roller feeds the first page of the document into the

feeder.

The scan motor stops when the leading edge of the page actuates

the document scan sensor. The page is now in the scan position.

The drive feed roller assembly rubber pad prevents multiple sheets

from being fed. A spring provides force that the pad places on the

document pages for proper separation.

The scan motor is turned on when the machine is ready to scan the

document and drives the feed roller at a speed determined by the

resolution selected. The scan motor stops after a set period of timewhen the trailing edge of the page releases the document scan

sensor. If another page is detected as the trailing edge of the page

releases the document scan sensor, the next page feeds to the scan

position. The exit roller pushes the page out onto the document exit

tray where it is stacked.

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Contact Image Sensor (CIS)

The contact image sensor unit consist of LEDs, rod lens array, and a

photo sensor. The LEDs illuminate the document to be scanned

when the leading edge is detected by the document scan sensor.

The LEDs turn off when the document exits the scanner mechanism.

The LEDs illuminate the document to obtain an image from the

document through the rod lens array, where the image is translated

into voltage levels.

Document Sensors

There are two document sensors in the scanner mechanism; the

document detect and the document scan sensor. The document

detect sensor, detects whether or not a document is loaded, and the

document scan sensor detects the scan position of the document.

The scanner mechanism consists of components which feed, scan,

and eject the documents that are to be copied or transmitted to a

remote facsimile unit.

Service Mode

In service mode (tech) mode, the technician checks the machine

and performs various tests to isolate the cause of a malfunction.

To enter the service mode, press Menu,#, 1, 9, 3, 4in sequence,

and the LCD briefly displays T. The machine has entered service

(tech) mode. While in service mode, the machine still performs all

normal operations. To return to normal user mode, press Menu, #, 1,9, 3, 4 in sequence again, or turn the power off and then on by

unplugging and plugging the power cord.

Options changed while in service mode do not remain changed

unless you clear the machine memory.

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Diagnostic Aids 3-3

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Setting up System in User Mode

Setup Item Default

Date Jan/01/01Time 12:00:00P

Month - Day - YearHour - Minute - AM/PM

Jan/01/0112:00 PM

Print Report Fax ConfirmTransmit LogReceive LogSpeed Send ListSelf Test

Maintenance Cartridge CleanCartridge AlignScanner Init

Paper Size Letter/A4/Legal Letter

Ringer Volume Off/Low/Medium/High Medium

Fax Print Letter Quality/ Draft Quality

Letter Quality

Fax Forwarding Off/Forward/ Forwardand Print

Off

Fax Receive Mode FAX/TEL/ANS/FAX/ DRPD

ANS/FAX

Setup DRPD Learn

Auto Journal Yes / No

Dial Mode Pulse / Tone

Default Setting Fax TypeCopy SizeCopy CollateCopy ContrastCopy TypeCopy Paper Type

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Setting up System in Service Mode

Setup Item Default

CIS Test Red, Green, and Bluemaximum and minimumpeak levels

Aging Test Scanner Aging/ Printer Aging

Print Report Fax ConfirmTransmit Log

Receive LogSpeed Send ListSelf TestProtocol DumpASF TestSystem DataNVRAM DumpCIS Pattern

Maintenance Cartridge Clean

Cartridge AlignScanner INIT

Program Download

Message Confirm On/Off/Error On-Error

Remote RCV Code (0-9) 9

EMC Mode Yes/No Yes

Auto Reduction On/Off Vertical Only On

Retry Interval (1-7) 3

Retry Count (0-2) 2

Answer on Rings (1-7) 1

Print RTI Yes / No

Modem Test FSK/2400/4800/7200/ 9600/12000/14400 bps/21600 bps/26400 bps/28800 bps/31200 bps/33600 bps/1100/1650/1850/2100 Hz

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CIS Test

The test adjusts the light of CIS. It is already set at CIS Test to get

optimum quality.

Warning:Shading profile must be made after downloading a new

firmware. If not, the system will not work properly.

1. Load all white document in scanner unit.

2. Press Setupand CIS Test Press Startis displayed.

3. Press Startand Shading...is displayed.

4. After scanning, shading waveform is printed.

5. After shading waveform has printed, press Stop.

6. Turn off system and turn on.

Aging Test

Scanner Aging - Scanner part aging

Printer Aging - Printer part aging.

Print Report

1. Press Setup.2. Press Menuuntil Print Reportis displayed.

3. Press Optionsto select the log you want to print.

4. Press Startor Setupto print the report.

DTMF Test

ROM Test

Modem Speed Item(1-6)

FSK/2400/4800/7200/9600/112000/14400/33600/12000/9600/7200/4800/2400

33600 bps

Set TX Level (1-15) 12

Set RX Level (40-50) 43

Pause Time (1-9) 3

Setup Item Default

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Maintenance

1. Press Setup.

2. Press Menuuntil Maintenancedisplays.

3. Press Optionsto select, cartridge clean, cartridge align and

scanner init.

4. Press Startafter you select.

Program Download

1. Press Setup.

2. Press Menufour times until Program Download Press Startis

displayed.

3. Press Start.

4. Download your new firmware files from PC.

Note: Be sure the USB cable is connected to the PC when you are

running this test. If cable is not connected, it may cause a fatal error.

Message Confirm

A message confirmation report shows whether the transmission wassuccessful or not and how many pages were sent.

1. Press Setup.

2. Press Menufive times until Message Confirm, Report, On

Report, Off Report, Erroris displayed.

3. Press Optionsto print a confirmation report automatically each

time you send a fax (On). Press Optionsto turn this feature off.

Press Optionsto print only when an error occurs and thetransmission was not successful. Press Startor Setupto set

the time you want to select.

Auto Journal

A journal shows specific information concerning transmission or

reception activities, the time and dates of up to 40 of the most recent

transmissions or receptions.

1. Press Setup.

2. Press Menuuntil Auto Journaldisplays in the top line of the

LCD.

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3. Press Optionsto print the journal automatically after every 40

transmissions or receptions (Yes). Press Optionsto print

journal manually (No).

Remote RCV Code

The remote receive code lets you initiate fax received from an

extension phone plugged into the EXT jack. If you pick up the

extension phone and hear fax tones, enter the remote receive code

and the fax starts receiving. The password is preset to 9.

1. Press Setup.

2. Press Menuuntil Remote RCV Codedisplays on the top line.3. Enter the code you want, 0 to 9 on the number keypad.

Dial Mode

Select the type of dial system your fax machine is connected to.

1. Press Setup.

2. Press Menuuntil Dial Modedisplays in the top line of the LCD.

3. Press Startor setupwhen Tone Message is displayed if the fax

machine is connected to a tone (Touch Tone) dial line.

4. Press Startor Setupwhen Pulse Message is displayed if the

fax machine is connected to a pulse (Rotary) dial line.

ECM (Error Correction Mode)

This mode compensates for poor line quality and ensures accurate,

error-free transmission with another ECM-equipped facsimilemachine. If the line quality is poor, transmission time may be

increased when ECM is enabled.

1. Press Setup.

2. Press Menuuntil ECM Modedisplays.

3. Press Startor Setupwhen Yes is displayed to turn on the Error

Correction Mode. Press Startor Setupwhen No is displayed to

turn off the Error Correction Mode.

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Auto Reduction

When receiving a document as long or longer than the paper

installed in your machine, the machine can reduce the data in the

document to fit into your recording paper size.

Turn on this feature if you want to reduce an incoming page that may

otherwise need to be divided into two pages with only a small portion

on the second page. If the fax machine cannot reduce the data to fit

one page with the feature enabled, the data is divided and printed in

actual size on two or more sheets.

1. Press Setup.2. Press Menuuntil Auto Reductiondisplays. To turn only the

vertical reduction feature On, press Startor Setupwhen On is

displayed. The machine reduces an incoming page containing

overflow data only in vertical. Press Startor Setupwhen Off is

displayed to turn this feature on.

Discard Size

When receiving a document as long as, or longer than, the paperinstalled in your fax machine, you can set the fax machine to discard

any excess image at the bottom of the page to fit into the recording

paper size. If the receiving page is outside the margin you set, it

prints on two sheets of paper at the actual size. If the data is within

the margin, and the Auto Reduction feature is turned on, it reduces

to fit into the appropriate size paper (Discard does not take place). If

the Auto Reduction feature is turned Off or fails, the data within the

margin is discarded.

1. Press Setup.

2. Press Menuuntil Discard Sizedisplays in the top line of the

LCD.

3. Enter the length using the numbers on the keypad.

Retry Interval

1. Press Setup.

2. Press Menuuntil Retry Intervaldisplays.

3. Enter the number of minutes (from 1 to 7) using the numbers on

the keypad.

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Retry Count

1. Press Setup.

2. Press Menuuntil Retry Countdisplays.

3. Enter the number of attempts (from 1 to 2) to redial the number.

If you enter 0, the machine does not redial.

Answer On Rings

You can select the number of times your machine rings before

answering an incoming call. If you are using your machine as both a

telephone and a fax machine, we suggest you set the ring count to at

least 4 to give you time to answer.

1. Press Setup.

2. Press Menuuntil Answer On Ringsdisplays.

3. Enter a number from 1 through 7 on the keypad.

Print RTI (Receive Terminal ID)

This feature lets the machine automatically print the receive terminalID (if registered), page number, and the date and time of the

reception at the bottom of each page on the received document.

1. Press Setup.

2. Press Menuuntil Print RTIdisplays.

3. Press Startfor yes to print RTI, or press Cancelfor no.

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3-10 Service Manual

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Modem Test

The modem sends various transmit signals on the telephone line.

You can check the following:

FSK

Tones: 1100Hz, 1650Hz, 1850Hz, 2100Hz

G3 training: 33600, 31200, 28800, 26400, 21600, 14400,

12000, 9600, 7200, 4800, 2400 bps

1. Press Setup.

2. Press Menuuntil Modem Testdisplays.

DTMF Test

This feature lets the user or tester verify that the phone keypad

buttons are working correctly.

1. Press Setup.

2. Press Menuuntil DTMF Testdisplays.

3. Press Start.

To test each button, press each button one at a time. There is a

different tone for each button. Each pressed button displays a

corresponding number or symbol in the LCD. If any button fails,

replace the operator panel.

ROM Test

Display ROM version and checksum.

1. Press Setup.

2. Press Menuuntil ROM Testdisplays.

3. Press Startor Setup.

Modem Speed

Default=33600 bps

Select baud rate of 33600, 28800, 14400, 12000, 9600, 7200, 4800

or 2400 bps. The lower the baud rate, the larger the acceptable error

rate. T30 protocol has a fixed speed of 300 bps in the protocol mode.

When the TX speed is set to 33600 or 28800 bps, the RX speed is

either V.34 V.17 or V.33. When the TX speed is set to 14400 or

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12000 bps, the RX speed is either V.17 or V.33. When the TX speed

is set to 9600 or 7200 bps, the RX speed is V.29 or V.27. When the

TX speed is set to 4800 or 2400 bps, the RX speed is V.27.

1. Press Setup.

2. Press Menuuntil Modem Speeddisplays.

3. Press Optionsto select the TX speed you want. Press Startor

Setup.

Set TX Level

Default=12 dBm

FCC requires that the transmission level be less than -9 dBm. From -

9 dBm to -15 dBm is acceptable. You can set the transmission level

between 0 and -15 dBm in 1 dBm steps using the operator panel

keypad. Accuracy is +0/-3 dBm.

1. Press Setup.

2. Press Menuuntil Set TX Leveldisplays.


Set RX Level

Default=-43 dBm

Reception level may be too low due to cable losses. If set to -43

dBm, reception sensitivity is between 0 and -43 dBm.

1. Press Setup.2. Press Menuuntil Set RX Leveldisplays.


Pause Time

Default=3 seconds

This sets the length of the pause time from 1 through 9 seconds.

1. Press Setup.

2. Press Menuuntil Pause Timedisplays.


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Repair Information 4-1

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4. Repair Information

This chapter explains how to make adjustments to the printer andhow to remove defective parts.

Note: Read the following before handling electronic parts.

Handling ESD-Sensitive Parts

Many electronic products use parts that are known to be sensitive to

electrostatic discharge (ESD). To prevent damage to ESD-sensitive

parts, follow the instructions below in addition to all the usualprecautions, such as turning off power before removing logic boards:

Keep the ESD-sensitive part in its original shipping container (aspecial ESD bag) until you are ready to install the part into the

machine.

Make the least-possible movements with your body to preventan increase of static electricity from clothing fibers, carpets, and

furniture.

Put the ESD wrist strap on your wrist. Connect the wrist band tothe system ground point. This discharges any static electricity in

your body to the machine.

Hold the ESD-sensitive part by its edge; do not touch its pins. Ifyou are removing a pluggable module, use the correct tool.

Do not place the ESD-sensitive part on the machine cover or ona metal table; if you need to put down the ESD-sensitive part for

any reason, first put it into its special bag. Machine covers and metal tables are electrical grounds. They

increase the risk of damage because they make a discharge

path from your body through the ESD-sensitive part. (Large

metal objects can be discharge paths without being grounded.)

Prevent ESD-sensitive parts from being accidentally touched byother personnel. Install machine covers when you are not

working on the machine, and do not put unprotected ESD-

sensitive parts on a table. If possible, keep all ESD-sensitive parts in a grounded metal

cabinet (case).

Be extra careful in working with ESD-sensitive parts when coldweather heating is used because low humidity increases static

electricity.

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Adjustments

The user is directed, in the Printer Control program, to perform the

bidirectional alignment adjustments after replacing a print cartridge.

Removal Procedures

The following procedures are arranged according to the name of the

printer part discussed.

CAUTION: Unplug the power cord before removing any parts.

Releasing Plastic Latches

Many of the parts are held in place with plastic latches. The latches

break easily; release them carefully. To remove such parts, press the

hook end of the latch away from the part to which it is latched.

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Removals

General Precautions on Removals

When you disassemble and reassemble components, use extreme

caution. The close proximity of cables to moving parts makes proper

routing a must. If components are removed or replaced, any cables

disturbed must be replaced as close as possible to their original

positions. Before removing any component from the machine, note

the cable routing.

When servicing the machine:

Check to verify that documents are not stored in memory. Move the printer cartridge to far right to cap the nozzle. Unplug the power cord. Use a flat and clean surface. Replace only with authorized components. Do not force plastic-material components.

Make sure all components are in their proper position.

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CIS White Roller Assembly Removal

1. Open the operator panel.

2. Push the bushing on both ends of the roller slightly inward, andthen rotate it until it reaches the slot as shown. Lift the roller out.

Note: If the roller is dirty. If dirty, wipe it with a soft cloth

dampened with water. If the roller is heavily worn, replace it with

a new one.

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Top Cover Assembly Removal

1. Open the operator panel and open the print cartridge

compartment cover. Remove the white roller assembly. Remove

the six screws as shown.

2. Remove the three screws as shown and remove the top cover

assembly.

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Rollers (Drive Feed Roller Assembly, Exit Shaft)Removal

1. Remove the top cover assembly. See Top Cover AssemblyRemovalon page 4-5.

2. Take out the rollers from the base assembly.

Note: Clean the surface of the rollers with ethyl alcohol. After wipingthem, you must dry them completely.

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CIS (Contact Image Sensor) Removal


2. Remove the drive feed roller. See Rollers (Drive Feed RollerAssembly, Exit Shaft) Removalon page 4-6.

3. Remove one screw securing the CIS assembly and unplug the

CIS harness. Remove the CIS assembly.

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4. Turn the CIS assembly over. Remove one screw to release the

CIS from the bracket.

Note: Be careful not to lose the springs.

Note: Check the glassy surface of the CIS for any stain or scratch. If

stained, wipe off with ethyl alcohol. If it is heavily stained or

scratched, replace it.

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Scanner Motor with Gear Assembly Removal


2. Unplug the motor connector from the system board. Make sure

the harness is released from hooks securing the harness as

shown.

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3. Remove two screws as shown and remove the scan motor

assembly.

4. Remove the two screws securing the motor to the motor

bracket.

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Power Supply Removal


2. Remove screw from left side and the ground wire on the right.

3. Disconnect connector CON1 from power supply.

4. Lift up and remove.

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Line Interface Board Removal


2. Remove the one screw securing the ground wires to the

bracket.

3. Unplug the line interface connector from the line interface

board.

4. Remove the screw from the ground wire on the power supply.

5. Pull the snaps as shown to unlock the line interface board from

the system board. Push up on the line interface board.

6. Unplug all the connectors from the line interface board and

remove it.

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Operator Panel Assembly Removal


2. Disconnect the operator panel cable from the system board.

3. Release harness from harness hook.

4. Remove the two ground strap screws.

5. Turn the tie stopper 90 degrees as shown and remove from

operator panel assembly.

6. Release ground strap cable hooks.

7. Release opposite operator panel hinge.

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Printer Unit Removal


2. Remove the paper support extension.

3. Release lower paper guide tabs.

4. Release upper paper guide tab.

5. Remove the paper guide.

6. Remove the paper deflector.

7. Remove three screws securing the printer unit, and unplug the

eight connectors from the system board. Remove the printer

unit.

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8. Remove ground strap screw.

Note: When you reassemble the unit, do not pinch or short the wire

harness.

ASF Assembly Removal


2. Remove paper support extension.

3. Release lower paper guide tabs.

4. Release upper paper guide tab.

5. Remove paper guide.

6. Remove paper deflector.

7. Release cables from guides located on ASF assembly.

8. Remove two screws.

9. Remove power supply. SeePower Supply Removalonpage 4-11.

10. Remove the three screws from the ASF assembly.

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11. Remove ASF assembly.

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Maintenance Station Removal

1. Remove the printer unit.

2. Remove one screw.3. Release two tabs from the rear of the maintenance station and

remove the maintenance station.

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Carrier Assembly with Belt Removal

1. Remove the printer unit. See Printer Unit Removalonpage 4-14.

2. Disconnect the carrier cables from the system board.

3. Release tab on carrier cable guide.

4. Release carrier cable guide from frame.

5. Remove pulley stopper.

6. Depress the belt tensioner and remove the belt from the carrier

motor.

7. Remove two carrier springs that secure the shaft.

8. Remove the carrier shaft.

9. Remove the carrier assembly.

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System Board Removal


2. Remove two screws securing the system board.

3. Unplug all connectors.

4. Pull the sensor lever toward you and remove the system board.

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Mid Frame Assembly with Exit Rollers Removal

1. Remove the top cover. See Top Cover Assembly Removalon page 4-5.

2. Remove the carrier assembly.

3. Remove the maintenance station.

4. Remove the encoder strip.

5. Remove two screws from friction roller assembly.

6. Remove exit roller assembly.

7. Release four springs on small feed roller assembly.

8. Press down and remove each lower portion section of the small

feed roller assembly.

9. Release tabs in upper portion of small feed roller assembly.

10. Remove upper portion of small feed roller assembly.

11. Push up on mid frame assembly to release from large feed

roller.

12. Remove mid frame assembly.

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Large Feed Roller Assembly with Gear Removal


2. Remove the mid frame assembly. See Mid Frame Assemblywith Exit Rollers Removalon page 4-20.

3. Remove the maintenance station.

4. Remove the feed roller bearing from the main frame. Pull the

feed roller as shown and remove.

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Paper Feed Motor Assembly with Gears Removal


2. Remove the large feed roller assembly. See Large FeedRoller Assembly with Gear Removalon page 4-21.

3. Remove the two screws and remove the paper feed motor

assembly.

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Carrier Transport Motor Removal

1. Remove the top cover assembly. Go to the Top CoverAssembly Removalon page 4-5.

2. Manually move the carrier to the center of the machine.

3. Remove the idler pulley assembly spring cover retainer.

4. Press the idler pulley and remove the belt from the carrier

transport pulley.

5. Disconnect connector (P4) from the system board.

6. Remove the two screws from the carrier transport motor and

remove.

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Connector Locations 5-1

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5. Connector LocationsSystem Board

Units Description

P1 Power Supply

P2 CIS

P4 Carrier Motor

P5 Paper Feed Motor

P6 Scanner Motor

P7 Carrier Cable

P8 Line Interface Board

P9 Operator Panel

P10 Speaker

P11 Door Switch

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Line Interface Board

Units Description

P1 System Board

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Connector Locations 5-3

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Power Supply

Units Description

CON1 System Board

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Preventive Maintenance 6-1

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6. Preventive Maintenance

This chapter contains the lubrication specifications. Follow theserecommendations to prevent problems and maintain optimum

performance.

Lubrication Specifications

Lubricate only when parts are replaced or as needed, not on a

scheduled basis. Use grease P/N 99A0394 to lubricate the following:

All gear mounting studs. The left and right ends of the large feed roller at the side frames. The carrier to carrier frame engagement. The carrier guide rod and carrier guide rod bearings.

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Parts Catalog 7-1

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7. Parts Catalog

How to Use This Parts Catalog

SIMILAR ASSEMBLIES: If two assemblies contain amajority of identical parts, they are shown on the same list.

Common parts are shown by one index number. Parts

peculiar to one or the other of the assemblies are listed

separately and identified by description.

NS: (Not Shown) in the Asm-Index column indicates that thepart is procurable but is not pictured in the illustration.

PP: in the parts description column indicates the part isavailable in the listed parts packet.

NA: Not available as a FRU.

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Assembly 1: Main Assembly

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Parts Catalog 7-3

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Assembly 1: Main Assembly

Asm-Index

PartNumber

Units Description

1-1 NA 1 Support, Paper Extension

2 56P1151 1 Guide, Paper

3 NA 1 Deflector, Paper

4 56P1154 1 Cover, Top Assembly

5 NA 1 CIS White Roller Assembly

6 56P1155 1 Tray, Paper Exit Assembly

7 56P1156 1 Tray, Scan Exit Assembly

8 NA 1 Screw/Rings Parts Packet

9 56P1160 1 Panel, Operator Assembly

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Assembly 2: Base Unit

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Parts Catalog 7-5

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Assembly 2: Base Unit

Asm-Index

PartNumber

Units Description

2-1 NA 1 Phone Line Cord

2 NA 1 Power Line Cord

3 56P1157 1 Board, Line Interface

3 56P1180 1 Board, Line Interface (EMEA)

3 56P1181 1 Board, Line Interface (Taiwan)

3 56P1182 1 Board, Line Interface (PRC)

4 56P1158 1 Power Supply

5 56P1161 1 Base Assembly

6 56P1164 1 Motor, Scanner with Gear Assembly

7 56P1165 1 Motor, Carrier Assembly

8 NA 1 Shaft, Exit

9 12G6941 1 Drive Feed Roller Assembly

10 NA 1 Strap, Operator Panel Door

11 NA 1 Spring, Ground

12 NA 1 Sensor, Access Door

13 NA 1 Latch, Operator Panel Door

14 56P1162 1 Contact, Image Sensor (CIS)

15 NA 1 Spring, CIS

16 NA 1 IPR-Bracket CIS17 56P1179 1 Cable CIS

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Assembly 3: Engine

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Assembly 3: Engine

Asm-Index

PartNumber

Units Description

3-1 56P1167 1 ASF Assembly

2 12G6961 1 Small Feed Roller Assembly with EOF andSprings

3 56P1159 1 System Board

4 NA 1 Main Frame Assembly with Encoder Clip

5 56P1169 1 Cable, Transport Carrier Motor

6 56P1168 1 Motor, Carrier Transport

7 NA 1 Spring, Carrier Shaft Retainer

8 12G6956 1 Maintenance Station Assembly

9 NA 1 Bearing, Feed Roller

10 12G6962 1 Feed Roller, Large with Gear

11 NA 1 Frame, Mid Assembly with Exit Rollers

12 NA 1 Carrier Belt

13 12G6968 1 Strip, Encoder

14 56P1170 1 Carrier Assembly with Belt

15 56P1173 1 Clip, Encoder

16 NA 1 Shaft, Carrier

17 NA 1 Stopper Pulley

18 12G6958 1 Pulley, Idle Assembly19 12G6963 1 Motor, Paper Feed Assembly with Gears

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Index I-1

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Index

AAbbreviations 1-5Adjustments 4-2Aging Test 3-5Answer On Rings 3-9Auto Journal 3-6Auto Reduction 3-8

C

CIS Test 3-5Connector Locations 5-1Contact Image Sensor 3-2

D

Diagnostic Aids 3-1Diagnostic Information 2-1Dial Mode 3-7

Discard Size 3-8Drive Feed Roller 3-1DTMF Test 3-10

E

ECM 3-7ESD-Sensitive Parts 4-1

G


L

Line Interface Board 5-2Lubrication Specifications 6-1

M

Maintenance 3-6

Message Confirm 3-6Modem Speed 3-10Modem Test 3-10

P

Parts Catalog 7-1Pause Time 3-11

Plastic Latches 4-2POST 2-1Power Supply 5-3Preventive Maintenance 6-1Print Report 3-5Print RTI 3-9Problems

Carrier Transport 2-3Maintenance Station 2-3Operator Panel 2-3Paper Feed 2-6Power 2-6Print Quality 2-6Printer Communication 2-5Scanner 2-5

Program Download 3-6

R

Remote RCV Code 3-7Removal Procedures 4-2Removals

ASF Assembly 4-15Carrier Assembly 4-18Carrier Transport Motor 4-23CIS White Roller 4-4Contact Image Sensor 4-7Large Feed Roller 4-21

Line Interface Board 4-12Maintenance Station 4-17Mid Frame Assembly 4-20Operator Panel 4-13Paper Feed Motor 4-22Power Supply 4-11Printer Unit 4-14Rollers 4-6Scanner Motor 4-9

System Board 4-19Top Cover Assembly 4-5

Repair Information 4-1Retry Count 3-9Retry Interval 3-8ROM Test 3-10

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S

Safety Information vService Checks

Carrier Transport 2-7CIS Assembly 2-9Maintenance Station 2-11Paper Feed 2-12Paper Path 2-14Power 2-15Print Quality 2-16Scan/Copy Quality 2-18Scanner Motor 2-10

Service Mode 3-2, 3-4Set RX Level 3-11Set TX Level 3-11Specifications

Facsimile 1-3Power and Size 1-5Printer Engine 1-2Printhead 1-2Scanner 1-5

Symptom Table (POST) 2-2Symptom Tables 2-3System Board 5-1

T

Theory of Mechanism

Contact Image Sensor 3-2Document Sensors 3-2Drive Feed Roller Assembly 3-1

Scanner 3-1

U

User Mode 3-3

P N b

56P1155 7-356P1156 7-356P1157 7-556P1158 7-5

56P1159 7-756P1160 7-356P1161 7-556P1162 7-556P1164 7-556P1165 7-556P1167 7-756P1168 7-756P1170 7-7

56P1173 7-756P1179 7-556P1180 7-556P1181 7-556P1182 7-5